JPH1016133A - Forming method for composite structure and composite - Google Patents

Forming method for composite structure and composite

Info

Publication number
JPH1016133A
JPH1016133A JP9057351A JP5735197A JPH1016133A JP H1016133 A JPH1016133 A JP H1016133A JP 9057351 A JP9057351 A JP 9057351A JP 5735197 A JP5735197 A JP 5735197A JP H1016133 A JPH1016133 A JP H1016133A
Authority
JP
Japan
Prior art keywords
leading edge
core structure
composite
fluoroelastomer
metal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
JP9057351A
Other languages
Japanese (ja)
Other versions
JP2828168B2 (en
Inventor
Louis Blackburn
ブラックバ−ン ルイス
J Hertel Christopher
ジェイ．ハーテル クリストファー
J Klein John
ジェイ．クライン ジョン
J Parkos Joseph Jr
ジェイ．パーコス ジェイアール． ジョセフ
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Raytheon Technologies Corp
Original Assignee
United Technologies Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by United Technologies Corp filed Critical United Technologies Corp
Publication of JPH1016133A publication Critical patent/JPH1016133A/en
Application granted granted Critical
Publication of JP2828168B2 publication Critical patent/JP2828168B2/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/72—Cured, e.g. vulcanised, cross-linked
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B32B2309/025—Temperature vs time profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12—Pressure
    • B32B2309/125—Pressure vs time profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2327/00—Polyvinylhalogenides
    • B32B2327/12—Polyvinylhalogenides containing fluorine
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2603/00—Vanes, blades, propellers, rotors with blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/20—Rotors
    • F05D2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F05D2240/303—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor related to the leading edge of a rotor blade
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49336—Blade making
    • Y10T29/49337—Composite blade
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24777—Edge feature
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/24995—Two or more layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/24995—Two or more layers
    • Y10T428/249951—Including a free metal or alloy constituent
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/24995—Two or more layers
    • Y10T428/249952—At least one thermosetting synthetic polymeric material layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
    • Y10T428/2852—Adhesive compositions
    • Y10T428/2878—Adhesive compositions including addition polymer from unsaturated monomer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31511—Of epoxy ether
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31511—Of epoxy ether
    • Y10T428/31529—Next to metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/3154—Of fluorinated addition polymer from unsaturated monomers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/3154—Of fluorinated addition polymer from unsaturated monomers
    • Y10T428/31544—Addition polymer is perhalogenated
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2926—Coated or impregnated inorganic fiber fabric
    • Y10T442/2984—Coated or impregnated carbon or carbonaceous fiber fabric

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Laminated Bodies (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Adhesives Or Adhesive Processes (AREA)

Abstract

PROBLEM TO BE SOLVED: To provide a method of forming a composite structure such as a vane-shaped structural body and a composite structure formed by the method. SOLUTION: A forming method consists of a step of providing an uncured core structure 12 formed of a non-metal material, a step of forming a material layer 14 for an uncured fluoroelastomer film on the surface of the section of the core structure 12, a step of disposing a metal structure 16, the inner face of which is brought into contact with the material layer 14 on a part of the core structure 12 and a step of forming a composite structure under heat and pressure for the time sufficient for current the core structure body 12 and the material layer 14 together and forming the both between the metal structure 16 and the material layer 14. The composite structure can be used for repairing a metal/composite structure such as a fan outlet guide vane for a jet engine, manufacturing an original metal/composite structure and the like by the arrangement.

Description

【発明の詳細な説明】DETAILED DESCRIPTION OF THE INVENTION

【０００１】[0001]

【発明の属する技術分野】本発明は、腐食および異物損
傷に対する優れた保護が図れる複合構造体（composite
structure ）の形成方法、およびこの複合構造体により
構成される複合物に関するものである。本発明の方法
は、翼形（airfoil ）構造体の製造および改修に特に有
用である。FIELD OF THE INVENTION The present invention relates to a composite structure having excellent protection against corrosion and foreign matter damage.
Structure), and a composite constituted by the composite structure. The method of the present invention is particularly useful for manufacturing and retrofitting airfoil structures.

【０００２】[0002]

【発明が解決しようとする課題】ジェットエンジン上の
ファン出口のガイドべーン（guide vane）のような複合
翼形構造体は、大気の影響による腐食、並びにべーンの
前縁（leading edge）上における異物の衝突から生じる
損傷を受ける。これらの翼形構造体を修復するための適
切な技術を見出すための研究がなされており、腐食およ
び異物に対する必要な保護が図れるとともに、十分な接
着構造体とすることができる改修方法が要望されてい
る。Composite airfoil structures, such as a fan exit guide vane on a jet engine, can cause corrosion due to atmospheric effects as well as leading edges of the vane. ) Suffer damage from the impact of foreign matter on it. Research has been conducted to find appropriate techniques for repairing these airfoil structures, and there is a demand for a repair method that can provide the necessary protection against corrosion and foreign substances and can provide a sufficient bonded structure. ing.

【０００３】よって、本発明の目的は、翼形構造体のよ
うな複合構造体における前縁を改修するための方法を提
供することにある。本発明の他の目的は、経済的に有利
であり、二次的な接着作業の必要のない上記の方法を提
供することにある。本発明のさらに他の目的は、複合構
造体の前縁上における腐食および異物損傷に対する優れ
た保護が図れる上記の方法を提供することにある。本発
明の別の目的は、元の金属／複合構造体の構成にも役立
つ上記した方法を提供することにある。本発明のさらに
別の目的は、十分に接着された複合構造体を提供するこ
とにある。上記の各目的は、本発明の方法により達成で
きる。Accordingly, it is an object of the present invention to provide a method for modifying a leading edge in a composite structure such as an airfoil structure. It is another object of the present invention to provide such a method which is economically advantageous and does not require a secondary bonding operation. Yet another object of the present invention is to provide such a method which provides excellent protection against corrosion and foreign object damage on the leading edge of the composite structure. It is another object of the present invention to provide a method as described above, which is also useful for constructing the original metal / composite structure. It is yet another object of the present invention to provide a fully bonded composite structure. Each of the above objects can be achieved by the method of the present invention.

【０００４】[0004]

【課題を解決するための手段】本発明によれば、複合構
造体を形成するための新規な方法が提供される。本方法
は、未硬化（uncure）あるいは実質的に未硬化状態の非
金属材料から形成されたコア構造体を用意するステッ
プ、前記コア構造体の表面部分上に、同様に好ましくは
未硬化あるいは実質的に未硬化の状態でありコア構造体
の材料の硬化温度と近い硬化温度を有するフルオロエラ
ストマー（fluoroelastomer ）のフィルムを形成するス
テップ、前記コア構造体の部分上に、その内面が前記フ
ルオロエラストマーのフィルムと接触する金属構造体を
配置するステップ、並びに前記非金属コア構造体材料お
よび前記フルオロエラストマーのフィルムを共に硬化
（co-cure ）し前記金属構造体と前記フルオロエラスト
マーのフィルム間に結合を形成するために、十分な時間
の間、熱と圧力下で前記複合構造体を成形（molding ）
するステップ含んでなる。好ましい実施の形態において
は、約３６０°Ｆ（１８２℃）までの温度および約１０
０ｐｓｉ（７ｋｇ／ｃｍ2 ）から約１０００ｐｓｉ（７
０ｋｇ／ｃｍ2 ）の圧力が、共に硬化し接着する工程の
間において、約３０分間だけ複合構造体に対して加えら
れる。According to the present invention, there is provided a novel method for forming a composite structure. The method comprises the steps of providing a core structure formed from a non-metallic material in an uncured or substantially uncured state, comprising, preferably, uncured or substantially uncured on a surface portion of the core structure. Forming a film of fluoroelastomer in an uncured state and having a curing temperature close to the curing temperature of the material of the core structure, wherein on the portion of the core structure, the inner surface is formed of the fluoroelastomer. Placing a metal structure in contact with the film, and co-cure the non-metallic core structure material and the fluoroelastomer film together to form a bond between the metal structure and the fluoroelastomer film Molding the composite structure under heat and pressure for a sufficient period of time to
Steps. In a preferred embodiment, temperatures up to about 360 ° F. (182 ° C.) and about 10 ° F.
0 psi (7 kg / cm 2 ) to about 1000 psi (7
A pressure of 0 kg / cm 2 ) is applied to the composite structure for about 30 minutes during the curing and bonding process together.

【０００５】金属構造体が、イソプロピルアルコール溶
液のような溶剤でその内面を洗浄するとともに、その内
面から望ましくない酸化物および他の有害な材料を取り
除くために塩化第二鉄の酸性エッチング溶液（ferric c
hloride acid etching solution ）内で金属構造体をエ
ッチングし、また新しい酸化物の生成を防止するととも
に表面の接着特性を改善するために前記金属構造体の前
記内面を下塗（prime）して用意された場合、接着の方
法の間において特に強固な接着が形成されることが見出
された。下塗するステップは、好ましくは、クロム酸ス
トロンチウム（strontium chromate）のような不溶性の
腐食抑制剤を含むエポキシ樹脂溶液を前記面に塗ること
を含んでなる。[0005] The metal structure is cleaned with a solvent, such as an isopropyl alcohol solution, and the ferric chloride acidic etching solution (ferric chloride) to remove unwanted oxides and other harmful materials from the interior. c
The inner surface of the metal structure was primed to etch the metal structure in a hloride acid etching solution and to prevent the formation of new oxides and improve the adhesive properties of the surface. It has been found that particularly strong bonds are formed during the bonding process. The priming step preferably comprises painting the surface with an epoxy resin solution containing an insoluble corrosion inhibitor such as strontium chromate.

【０００６】本発明の方法は、ジェットエンジンに使用
されるファン出口ガイドべーンのような翼形構造体の改
修において特別の有用性を持つことが見出された。ま
た、元の機器の製造および金属／複合物構造体の形成に
おいても有用性を有する。本発明の方法は、従来技術に
おいては極めて困難であった、ステンレススチールへの
接着のための優れた技術であることが見出された。本発
明の方法のその他の詳細、および他の目的並びに付随し
た特徴は、以下の詳細な説明および添付した図面に説明
されている。添付図面において、同じ参照数字は同じ要
素を示している。The method of the present invention has been found to have particular utility in retrofitting airfoil structures such as fan exit guide vanes used in jet engines. It also has utility in the manufacture of original equipment and in the formation of metal / composite structures. The method of the present invention has been found to be an excellent technique for bonding to stainless steel, which was extremely difficult in the prior art. Other details and other objects and associated features of the method of the present invention are described in the following detailed description and the accompanying drawings. In the accompanying drawings, the same reference numerals indicate the same elements.

【０００７】[0007]

【発明の実施の形態】以下に本発明の実施の形態を詳細
に説明する。図１および図２は、本発明の方法を使用し
て形成された、ファン出口ガイドべーンのような、複合
構造体１０の前縁部分を例示したものである。複合構造
体１０は、好ましくは未硬化あるいは実質的に未硬化の
状態にある、非金属の複合材料から形成されたコア構造
体１２、同様に好ましくは未硬化または実質的に未硬化
の状態にあり、コア構造体１２の硬化温度に実質的に近
い硬化温度を有するフルオロエラストマーのフィルムの
材料層１４、並びにコア構造体の前縁部分１８の上に配
置された金属構造体１６を含んでいる。Embodiments of the present invention will be described below in detail. 1 and 2 illustrate a leading edge portion of a composite structure 10, such as a fan exit guide vane, formed using the method of the present invention. The composite structure 10 is preferably a core structure 12 formed of a non-metallic composite material, preferably in an uncured or substantially uncured state, as well as preferably in an uncured or substantially uncured state. And includes a material layer 14 of a film of fluoroelastomer having a curing temperature substantially close to the curing temperature of the core structure 12, as well as a metal structure 16 disposed on a leading edge portion 18 of the core structure. .

【０００８】複合構造体１０がファン出口ガイドべーン
に使用された場合、コア構造体１２は、約３５０°Ｆ
（１７７℃）の硬化温度を有する複合グラファイト−エ
ポキシ材料（composite graphite-epoxy material ）か
ら形成される。この材料は未硬化または実質的に未硬化
の状態であり、また１つまたはそれより多くのコアパイ
ル（core pile ）２０および１つまたはそれより多くの
シェルパイル（shell pile）２２から構成される。典型
的には、全てのコアパイル２０およびシェルパイル２２
は同じ複合材料から形成される。コア構造体１２は所望
の形状および厚さを有している。複合構造体がファン出
口ガイドべーンのような翼形構造体として使用される場
合には、コア構造体１２は好ましくは空気力学的な形状
を有している。[0008] If the composite structure 10 is used in a fan exit guide vane, the core structure 12 will be about 350 ° F.
Formed from a composite graphite-epoxy material having a curing temperature of (177 ° C.). The material is in an uncured or substantially uncured state and is composed of one or more core piles 20 and one or more shell piles 22. Typically, all core piles 20 and shell piles 22
Are formed from the same composite material. The core structure 12 has a desired shape and thickness. When the composite structure is used as an airfoil structure, such as a fan exit guide vane, the core structure 12 preferably has an aerodynamic shape.

【０００９】フルオロエラストマーのフィルムの材料層
１４は、約３５０°Ｆ（１７７℃）の硬化温度を有する
ＶＩＴＯＮフィルムから形成され、このフィルムは未硬
化または実質的に未硬化の状態である。このフィルム層
は通常は約０．００８インチから約０．０１５インチ
（約０．００２センチから約０．０３８センチ）の厚さ
を有している。ＶＩＴＯＮフィルムは、オハイオ州のＣ
ｕｙａｈｏｇａ ＦａｌｌｓのＥａｇｌｅ Ｅｌａｓｔ
ｏｍｅｒ社によって製造されたフルオロエラストマー製
品である（ＶＩＴＯＮはｄｕＰｏｎｔ社の登録商標であ
る）。なお、ＶＩＴＯＮフィルムは、フッ化ビニリデン
（vinylidene fluoride ）とヘキサフルオロプロピレン
（hexafluoropropylene ）の共重合体をベースとするフ
ルオロエラストマーのフィルムである。このフルオロエ
ラストマーのフィルムの材料層１４は接着剤として機能
し、また、業界において公知の適当な技術を使用して、
コア構造体１２の表面２４に形成される。例えば、コア
構造体の前縁の表面２４上にはけ塗り（brush ）あるい
は塗装（paint ）される。必要な場合には、フルオロエ
ラストマーのフィルムの層は、複合構造体１０の前縁を
越えた表面２４の部分に延在するように形成される。腐
食および異物損傷に対する保護を改善するために、金属
構造体１６つまり金属シース（metallic sheath ）が複
合構造体の前縁部分１８の上に配置されている。この金
属構造体１６は、ＡＭＳ ５５１０のような鉄をベース
とする合金材料、あるいはＡＭＳ ５５３６またはＡＭ
Ｓ ５５９９のようなニッケルをベースとする合金材料
から形成される。The fluoroelastomer film material layer 14 is formed from a VITON film having a curing temperature of about 350 ° F. (177 ° C.), which film is in an uncured or substantially uncured state. This film layer typically has a thickness of about 0.008 inches to about 0.015 inches (about 0.002 cm to about 0.038 cm). VITON film is available from C
Eagle Elast of uyahoga Falls
is a fluoroelastomer product manufactured by Omer (VITON is a registered trademark of duPont). The VITON film is a fluoroelastomer film based on a copolymer of vinylidene fluoride and hexafluoropropylene. The material layer 14 of the fluoroelastomer film functions as an adhesive and can be formed using any suitable technique known in the art.
It is formed on the surface 24 of the core structure 12. For example, the leading edge surface 24 of the core structure may be brushed or painted. If necessary, a layer of the fluoroelastomer film is formed to extend over the portion of the surface 24 beyond the leading edge of the composite structure 10. To improve protection against corrosion and foreign object damage, a metal structure 16 or metal sheath is disposed over the leading edge portion 18 of the composite structure. The metal structure 16 may be an iron-based alloy material such as AMS 5510, or AMS 5536 or AM
Formed from a nickel-based alloy material such as S5599.

【００１０】金属構造体１６は固体構造体であることが
好ましく、この固体構造体により腐食および異物損傷に
対するより良い保護が行える。金属構造体１６は、前縁
構造体として使用された場合、Ｖ形状で、また約０．０
０５インチから約０．０１２インチ（約０．０１３セン
チから約０．０３センチ）の範囲の厚さを有している。The metal structure 16 is preferably a solid structure, which provides better protection against corrosion and foreign object damage. The metal structure 16, when used as a leading edge structure, is V-shaped and has a
It has a thickness in the range of from about 05 inches to about 0.012 inches (about 0.013 cm to about 0.03 cm).

【００１１】複合構造体を形成するために、フルオロエ
ラストマーの接着剤の材料層１４は最初にコア構造体１
２の外側の表面２４の部分に形成される。上記したよう
に、接着材料は表面２４の部分上にフィルムの形態で形
成される。To form the composite structure, the fluoroelastomer adhesive material layer 14 is first applied to the core structure 1.
2 is formed on a portion of the outer surface 24. As mentioned above, the adhesive material is formed on the portion of the surface 24 in the form of a film.

【００１２】接着剤の材料層１４上に配置される前に、
前端の金属構造体１６は、金属構造体１６の内面２６を
活性化し、これにより金属構造体１６とコア構造体１２
の間に形成される接着を大幅に改善するための、重要な
前処理プロセスを受ける。この重要な前処理プロセス
は、金属構造体１６の内面２６を洗浄し、酸化物を取り
除いて接着のための清浄な面を提供するために内面２６
をエッチングし、また酸化物の形成を防止して最終的に
形成される接着の剥離強度（peel strength ）を改善す
るために内面２６を下塗することからなる。Before being placed on the adhesive material layer 14,
The metal structure 16 at the front end activates the inner surface 26 of the metal structure 16, whereby the metal structure 16 and the core structure 12 are activated.
Undergoes an important pre-treatment process to significantly improve the adhesion formed between them. This important pretreatment process cleans the inner surface 26 of the metal structure 16 and removes the oxide to provide a clean surface for bonding.
And to prime the inner surface 26 to prevent oxide formation and improve the peel strength of the final bond formed.

【００１３】好ましい前処理プロセスにおいては、金属
構造体１６の内面２６は最初に、試薬等級（reagent gr
ade ）のイソプロピルアルコールあるいはアセトンのよ
うな適当な溶剤で湿らせた清浄な、サイズの特定されな
いチーズクロスを使用して、清浄に拭き取りされる。拭
き取りの後、内面は周囲温度で空気乾燥されるかあるい
は最大２５０°Ｆ（１２１℃）で炉乾される。乾燥時間
は、接着プロセスに有害な清浄化溶剤の跡を取り除くの
に十分なものである。In a preferred pretreatment process, the inner surface 26 of the metal structure 16 is first treated with a reagent grade.
ade) is wiped clean using clean, unsized cheese cloth moistened with a suitable solvent such as isopropyl alcohol or acetone. After wiping, the inner surface is air dried at ambient temperature or oven dried at a maximum of 250 ° F (121 ° C). The drying time is sufficient to remove traces of cleaning solvents harmful to the bonding process.

【００１４】その後、内面は、面上の何らかの酸化物を
取り除き、接着のための清浄な面を提供するために、塩
化第二鉄酸エッチング溶液を使用してエッチングされ
る。エッチング溶液の適用の前に、金属構造体１６は、
Ｂｌｕｅ Ｇｏｌｄ Ｉｎｄｕｓｔｒｉａｌ Ｃｌｅａ
ｎｅｒの名称の商標で販売されているアルカリ洗浄剤あ
るいは同等なアルカリ洗浄剤をガロン当たり５オンス含
む溶液のようなアルカリ洗浄溶液内に浸漬される。金属
構造体は少なくとも５分間だけ溶液内に浸漬される。溶
液は好ましくは約１２０°Ｆ（４９℃）から約１６０°
Ｆ（７１℃）の範囲内の温度に維持される。アルカリ洗
浄溶液から取り除いた後、金属構造体１６は冷水内で２
０秒から４０秒の間だけ水洗される。The inner surface is then etched using a ferric chloride etching solution to remove any oxide on the surface and provide a clean surface for bonding. Prior to the application of the etching solution, the metal structure 16
Blue Gold Industrial Clear
It is immersed in an alkaline cleaning solution, such as a solution containing 5 ounces per gallon of an alkaline cleaner sold under the trademark ner or equivalent. The metal structure is immersed in the solution for at least 5 minutes. The solution is preferably from about 120 ° F. (49 ° C.) to about 160 °
The temperature is maintained within the range of F (71 ° C.). After removal from the alkaline cleaning solution, the metal structure 16 is
Rinsed only for 0 to 40 seconds.

【００１５】金属構造体の内面２６のエッチングは、金
属構造体を塩化第二鉄の酸性エッチング溶液内に浸漬す
ることにより行われる。エッチング溶液は、８０ガロン
（３０２．４リットル）の塩酸を用意し、１３５ｌｂｓ
（６１．３ｋｇ）の無水塩化第二鉄を少しづつ加え、混
合タンクを１２０°Ｆ（４９℃）より低い温度に維持す
ることにで作られる。溶液が約９０°Ｆ（３２℃）の温
度まで冷えた後、２ガロン（７．５６リットル）の硝酸
および１１ガロン（４１．６リットル）の水が加えられ
る。このエッチング操作は、好ましくは、室温で約１４
分から１６分の間だけ行われる。必要に応じて、内面２
６は、エッチングを開始する前に、２０ｐｓｉ（１．４
ｋｇ／ｃｍ2 ）の圧力で２４０メッシュの酸化アルミニ
ウムで研磨的あるいはグリットブラストされる。The etching of the inner surface 26 of the metal structure is performed by immersing the metal structure in an acidic etching solution of ferric chloride. As an etching solution, 80 gallons (302.4 liters) of hydrochloric acid were prepared, and 135 lbs.
(61.3 kg) of anhydrous ferric chloride in portions, and made by maintaining the mixing tank below 120 ° F (49 ° C). After the solution has cooled to a temperature of about 90 ° F (32 ° C), 2 gallons (7.56 liters) of nitric acid and 11 gallons (41.6 liters) of water are added. This etching operation is preferably performed at room temperature for about 14 hours.
It takes place only between minutes and 16 minutes. If necessary, inner surface 2
6 is 20 psi (1.4) before starting etching.
Abrasive or grit blasted with 240 mesh aluminum oxide at a pressure of kg / cm 2 ).

【００１６】エッチング操作が完了した後、金属構造体
は冷水中で約２０秒間から４０秒間の間だけすすぎ落と
しされ、その後、冷水を流して水洗される。内面２６は
次いで、汚れあるいは他の有害な粒子が検査される。汚
れあるいは他の有害な粒子が見付かった場合には、好ま
しくは、拭き取りなどにより手作業で取り除かれる。そ
の後、金属構造体はさらに冷水を流して水洗される。水
洗の後、金属構造体１６は好ましくは炉内に配置され、
また約１４０°Ｆ（６０℃）から約１６０°Ｆ（７１
℃）の範囲の温度において約１４分から１６分の範囲の
時間期間だけ乾燥される。After the etching operation is completed, the metal structure is rinsed off in cold water for about 20 to 40 seconds, and then rinsed with running cold water. Inner surface 26 is then inspected for dirt or other harmful particles. If dirt or other harmful particles are found, they are preferably removed manually, such as by wiping. Thereafter, the metal structure is further washed with cold water. After rinsing, the metal structure 16 is preferably placed in a furnace,
Also, from about 140 ° F (60 ° C) to about 160 ° F (71 ° C).
C.) for a time period ranging from about 14 minutes to 16 minutes.

【００１７】最後の前処理ステップとして、表面の酸化
を防止するとともに接着を改善するために内面２６が下
塗される。下塗の操作は、クロム酸ストロンチウム（st
rontium chromate）のような不溶性の腐食抑制剤を含む
エポキシ樹脂溶液を、内面２６に塗ることから構成され
る。下塗のエポキシ樹脂溶液を内面２６に塗るために業
界において公知の適当な技術が使用される。下塗材（pr
imer）は適当な条件（２５０°Ｆ（１２１℃）で３０分
間だけ空中）で硬化されなければならない。As a final pretreatment step, the inner surface 26 is primed to prevent oxidation of the surface and improve adhesion. The undercoating operation is performed by strontium chromate (st
An epoxy resin solution containing an insoluble corrosion inhibitor, such as rontium chromate, is applied to inner surface 26. Any suitable technique known in the art can be used to apply the primer epoxy solution to inner surface 26. Undercoat material (pr
The imer must be cured under suitable conditions (250 ° F (121 ° C) for 30 minutes in air).

【００１８】表面の前処理が完了した後は、金属構造体
１６は、フルオロエラストマーの接着剤の材料層１４と
接触する金属構造体の内面２６を備えたコア構造体１２
の前端部分の上に配置される。全体の複合構造体は次い
で、圧縮成形用金型のようなモールド（図示せず）の内
部に配置され、コア構造体１２を形成するエポキシ−グ
ラファイト材料およびフルオロエラストマーの接着剤の
材料層１４を共に硬化し、金属構造体１６のエッチング
され下塗された内面２６とフルオロエラストマーの接着
剤の材料層１４の間に比較的強固な接着を生成するため
に、３０分の時間だけ、熱と圧力を受ける。複合構造体
に加えられる圧力は好ましくは約１００ｐｓｉ（７ｋｇ
／ｃｍ2 ）から約１０００ｐｓｉ（７０ｋｇ／ｃｍ2 ）
の範囲内である。モールド内で複合構造体に加えられる
温度は３６０°Ｆ（１８２℃）を越えてはならない。典
型的には、共に硬化し接着する操作の間において約３５
０°Ｆ（１７７℃）の温度が使用される。After the surface pre-treatment is completed, the metal structure 16 is provided with a core structure 12 having an inner surface 26 of the metal structure in contact with the fluoroelastomer adhesive material layer 14.
Is disposed on the front end portion of the. The entire composite structure is then placed inside a mold (not shown), such as a compression mold, and a layer of epoxy-graphite material and a fluoroelastomer adhesive material 14 forming a core structure 12 is provided. Heat and pressure are applied for a period of 30 minutes to cure together and create a relatively strong bond between the etched primed inner surface 26 of the metal structure 16 and the fluoroelastomer adhesive material layer 14. receive. The pressure applied to the composite structure is preferably about 100 psi (7 kg).
/ Cm 2 ) to about 1000 psi (70 kg / cm 2 )
Is within the range. The temperature applied to the composite structure in the mold must not exceed 360 ° F (182 ° C). Typically, about 35 during the curing and bonding operation together
A temperature of 0 ° F. (177 ° C.) is used.

【００１９】ここで、金属構造体１６上で洗浄、エッチ
ングおよび下塗の各ステップを組合わせて行うことは、
成形操作の間において接着を行うために重要であること
が見出された。また、コア構造体材料と接着剤の層の材
料を共に硬化することにより、二次的な接着操作の必要
がなくなることが見出された。この結果、複合構造体を
作るためのコストが非常に減じられる。本発明の方法の
最終結果として、ファン出口ガイドべーンのような、複
合構造体の前縁上の良好に接着された金属シースを得る
ことができ、腐食および異物損傷の保護が改良される。Here, the combination of the steps of cleaning, etching and undercoating on the metal structure 16 is as follows.
It has been found to be important for the adhesion during the molding operation. It has also been found that co-curing the core structure material and the adhesive layer material eliminates the need for a secondary bonding operation. As a result, the cost for making the composite structure is greatly reduced. The end result of the method of the present invention is a well bonded metal sheath on the leading edge of the composite structure, such as a fan exit guide vane, with improved protection against corrosion and foreign object damage .

【００２０】当業分野において、以前は、ステンレスス
チールへの接着は非常に困難であることが知られてい
る。本発明の方法では、ＡＭＳ ５５１０のようなステ
ンレススチール材料を接着することができ、また、主に
ＶＩＴＯＮ接着剤層内で発生する破壊において約２０−
７０ｌｂｓ／ｉｎｃｈ幅（３．５８−１２．５ｋｇ／ｃ
ｍ幅）の範囲内の剥離強度を達成することができる。In the prior art, it has previously been known that adhesion to stainless steel is very difficult. With the method of the present invention, a stainless steel material such as AMS 5510 can be bonded, and about 20-
70 lbs / inch width (3.512.5 kg / c
m width).

【００２１】ＡＭＳ ５５１０のようなステンレススチ
ール材料を使用して形成された前縁は特に有利であるこ
とが見出された。これは小さな粒子の急断試験を使用し
て実証された。このテストにおいて、０．１２５インチ
（０．３２ｃｍ）径のスチールボールベアリングが、
０．０１２インチ（０．０３ｃｍ）の厚さのワイヤメッ
シュ前縁あるいは０．０１０インチ（０．０２５ｃｍ）
の厚さのステンレススチール前縁のいずれかを有するフ
ァン出口ガイドべーンの前縁に発射された。図３は、ワ
イヤメッシュ前縁と比べた場合においてステンレススチ
ール前縁が示す小さな粒子の衝突における改善度を示し
たものである。ワイヤメッシュの前縁は０．２５ｆｔ−
ｌｂ（０．０３５ｋｇ−ｍ）の粒子エネルギーで穴が開
けられた。ステンレススチール前縁は０．６ｆｔ−ｌｂ
（０．０８３ｋｇ−ｍ）までのエネルギーレベルの粒子
が衝突しても穴開きはなかった。０．２５ｆｔ−ｌｂ
（０．０３５ｋｇ−ｍ）において、ワイヤメッシュの前
縁と比べた場合において、ステンレススチールの前縁は
凹み深さが約４０％減じられた。凹み深さよりも重要な
ことには、ワイヤメッシュ前縁と比べた場合、ステンレ
ススチール前縁の場合は穴開けに必要なエネルギーが１
４０％よりも大きいことが実証された。A leading edge formed using a stainless steel material such as AMS 5510 has been found to be particularly advantageous. This was demonstrated using a small particle break test. In this test, a 0.125 inch (0.32 cm) diameter steel ball bearing
0.012 inch (0.03 cm) thick wire mesh leading edge or 0.010 inch (0.025 cm)
At the leading edge of a fan exit guide vane having any of the following thicknesses of stainless steel leading edge. FIG. 3 shows the improvement in small particle impact exhibited by the stainless steel leading edge when compared to the wire mesh leading edge. The leading edge of the wire mesh is 0.25 ft-
Holes were drilled with a particle energy of lb (0.035 kg-m). 0.6ft-lb stainless steel leading edge
(0.083 kg-m), there was no hole even if the particles collided with energy levels up to (0.083 kg-m). 0.25 ft-lb
At (0.035 kg-m), the stainless steel leading edge had a pit depth reduction of about 40% when compared to the wire mesh leading edge. More importantly than the recess depth is that the stainless steel leading edge requires 1 less energy to drill when compared to the wire mesh leading edge.
It has been demonstrated that it is greater than 40%.

【００２２】フルオロエラストマーのフィルムの延性特
性による、本発明の方法を使用して得られる剥離強度の
改良を実証するため、多数の複合材料の試験片が、成形
されたファン出口ガイドべーンから取り除かれた。各試
験片は、未硬化状態のエポキシ−グラファイトコア材
料、未硬化状態のＶＩＴＯＮ接着剤材料の中間層、並び
に上記した前処理プロセスを受け、接着剤材料の層の上
に配置された、ＡＭＳ５５１０ステンレススチール材料
の層を有する複合構造体で構成される。各試験片はベー
ン圧縮成形用金型（vane compression mold ）内に配置
され、また、コア材料とＶＩＴＯＮ接着剤材料を共に硬
化するとともにステンレススチール層をＶＩＴＯＮ材料
層に接合するために、３０分間だけ５００ｐｓｉ（３５
ｋｇ／ｃｍ2 ）の圧力および３５０°Ｆ（１７７℃）の
温度を受けた。To demonstrate the improvement in peel strength obtained using the method of the present invention due to the ductile properties of the fluoroelastomer film, a number of composite specimens were prepared from a molded fan exit guide vane. Removed. Each specimen was an uncured epoxy-graphite core material, an uncured intermediate layer of VITON adhesive material, and an AMS5510 stainless steel, which was subjected to the pre-treatment process described above and placed over the layer of adhesive material. Consists of a composite structure having a layer of steel material. Each specimen was placed in a vane compression mold and only 30 minutes to cure the core material and the VITON adhesive material together and bond the stainless steel layer to the VITON material layer. 500 psi (35
kg / cm 2 ) and a temperature of 350 ° F (177 ° C).

【００２３】試験片のいくつかは異なる条件を受けた。
１つの試験片は湿度条件（１４０°Ｆ（６０℃）／９５
％ＲＨ／１４日）を受けた。２つの試験片は２５０°Ｆ
（１２１℃）で５００時間だけエージングされた。他の
２つの試験片は０°Ｆ（−１８℃）から２５０°Ｆ（１
２１℃）の範囲の温度で１００サイクルだけ熱サイクル
された。その後、各試験片に対する剥離強度がＡＳＴＭ
Ｄ３１６７により決定された。製造された試験片は７
５°Ｆ（２４℃）において１６から３２ｌｂｓ／ｉｎｃ
ｈ（２．８６から５．７３ｋｇ／ｃｍ）幅の範囲内の剥
離強度を有していたが、湿度試験された試験片は７５°
Ｆ（２４℃）において４６ｌｂｓ／ｉｎｃｈ（８．２３
ｋｇ／ｃｍ）幅の剥離強度を有しており、エージング試
験された試験片は７５°Ｆ（２４℃）において２７ｌｂ
ｓ／ｉｎｃｈ幅（４．８３ｋｇ／ｃｍ幅）および４１ｌ
ｂｓ／ｉｎｃｈ幅（７．３４ｋｇ／ｃｍ幅）の剥離強度
を有しており、またサイクル試験された試験片は７５°
Ｆ（２４℃）において１８ｌｂｓ／ｉｎｃｈ幅（３．７
２ｋｇ／ｃｍ幅）および２１ｌｂｓ／ｉｎｃｈ幅（３．
７６ｋｇ／ｃｍ幅）の剥離強度を有していることが判っ
た。Some of the specimens underwent different conditions.
One specimen was subjected to humidity conditions (140 ° F. (60 ° C.) / 95
% RH / 14 days). 250 ° F for two test pieces
Aged at (121 ° C.) for 500 hours. The other two specimens were from 0 ° F (-18 ° C) to 250 ° F (1
Thermal cycling was performed for 100 cycles at a temperature in the range of 21 ° C.). Thereafter, the peel strength of each test piece was determined by ASTM.
D3167. 7 specimens were produced
16 to 32 lbs / inc at 5 ° F (24 ° C)
h (2.86 to 5.73 kg / cm), but the test piece subjected to the humidity test had a peel strength of 75 °.
46 lbs / inch (8.23) at F (24 ° C.)
kg / cm) wide peel strength and the aged test specimen was 27 lb at 75 ° F (24 ° C).
s / inch width (4.83 kg / cm width) and 41 l
It has a peel strength of bs / inch width (7.34 kg / cm width), and the test piece subjected to the cycle test is 75 °
18 lbs / inch width at F (24 ° C.) (3.7
2 kg / cm width) and 21 lbs / inch width (3.
(76 kg / cm width).

【００２４】試験結果はまた、本発明の方法により形成
されたステンレススチール前縁を備えた複合ファン出口
ガイドベーンの疲労強度が従来技術により形成された複
合ファンガイド出口ベーンおよびワイヤメッシュ前縁よ
りも大きいことを示している。The test results also show that the fatigue strength of the composite fan exit guide vane with the stainless steel leading edge formed by the method of the present invention is greater than the composite fan guide exit vane and wire mesh leading edge formed by the prior art. It is big.

【００２５】コア構造体１２は未硬化または実質的に未
硬化の状態であることが好ましいが、本発明は硬化され
たグラファイト−エポキシ材料のような硬化されたコア
材料で形成することもできる。Although the core structure 12 is preferably in an uncured or substantially uncured state, the present invention can also be formed with a cured core material, such as a cured graphite-epoxy material.

【００２６】以上、本発明を翼形構造体上の前縁に適用
した例を説明したが、本発明の方法は、一般的な金属に
おいて複合材料を接合する用途にも使用でき、したがっ
て例示した実施の形態に限定されない。また、本発明の
方法は、接着剤接合のための適当な表面の前処理をした
他の金属（チタン、アルミニウム、ニッケル）にも同様
に適用できる。さらに、本方法は修理プロセスと同様に
元の機器の製造プロセスにおいても有用なものである。While the present invention has been described with reference to the application of the present invention to a leading edge on an airfoil, the method of the present invention can also be used for joining composite materials in common metals, and is thus illustrated. The present invention is not limited to the embodiment. Also, the method of the present invention is equally applicable to other metals (titanium, aluminum, nickel) with suitable surface pretreatment for adhesive bonding. Further, the method is useful in the original equipment manufacturing process as well as in the repair process.

【００２７】[0027]

【発明の効果】以上の通り、本発明によれば、翼形構造
体のような複合構造体の前縁を改修するための方法を提
供できる。また、本発明の方法によれば、経済的に有利
であり、に二次的な接着作業の必要を排除できる。さら
に、本発明の方法によれば、複合構造体の前縁上におけ
る腐食および異物損傷の保護が改善される。さらに、本
発明によれば、元の金属／複合体構造体の構成にも役立
つ方法を提供できる。さらに、本方法によれば、十分に
接着された複合構造体を提供できる。As described above, the present invention provides a method for repairing the leading edge of a composite structure such as an airfoil structure. In addition, the method of the present invention is economically advantageous and eliminates the need for secondary bonding operations. Further, the method of the present invention provides improved protection against corrosion and foreign material damage on the leading edge of the composite structure. Further, according to the present invention, a method can be provided which is useful for the construction of the original metal / composite structure. Further, according to the present method, a sufficiently bonded composite structure can be provided.

【図面の簡単な説明】[Brief description of the drawings]

【図１】本発明に係わる複合翼形構造体の部分的な断面
図である。FIG. 1 is a partial cross-sectional view of a composite airfoil structure according to the present invention.

【図２】本発明に係わる複合構造体の前縁の拡大した断
面図である。FIG. 2 is an enlarged sectional view of a leading edge of the composite structure according to the present invention.

【図３】ワイヤメッシュおよびステンレススチールの前
縁を有するファン出口ガイドべーン上の行われた急断試
験の結果を示したグラフである。FIG. 3 is a graph showing the results of a snap test performed on a fan exit guide vane having a wire mesh and stainless steel leading edge.

【符号の説明】[Explanation of symbols]

１０ 複合構造体 １２ コア構造体 １４ フルオロエラストマーのフィルムの材料層 １６ 金属構造体 ２０ コアパイル ２２ シェルパイル ２４ 表面 ２６ 内面 DESCRIPTION OF SYMBOLS 10 Composite structure 12 Core structure 14 Fluoroelastomer film material layer 16 Metal structure 20 Core pile 22 Shell pile 24 Surface 26 Inner surface

───────────────────────────────────────────────────── フロントページの続き (72)発明者 クリストファー ジェイ．ハーテル アメリカ合衆国，コネチカット 06109, ウェザーズフィールド，サンセット ブー ルバード 64 (72)発明者 ジョン ジェイ．クライン アメリカ合衆国，コネチカット 06238, カベントリー，イーストビュー ドライブ 46 (72)発明者 ジョセフ ジェイ．パーコス ジェイアー ル. アメリカ合衆国，コネチカット 06423, イーストハダム，フィールドストーンズ ロード 60 ──────────────────────────────────────────────────続 き Continued on front page (72) Inventor Christopher Jay. Hartell United States, Connecticut 06109, Weathersfield, Sunset Boulevard 64 (72) Inventor John Jay. Klein United States, Connecticut 06238, Caventry, Eastview Drive 46 (72) Inventor Joseph Jay. Parkos Jr., Connecticut 06423, East Haddam, Fieldstones Road 60

Claims (18)

【特許請求の範囲】[Claims] 【請求項１】 複合構造体を形成するための方法におい
て、 未硬化の非金属複合材料から形成されたコア構造体を用
意するステップ、 前記コア構造体の表面部分上に未硬化のフルオロエラス
トマーのフィルムを形成するステップ、 前記コア構造体の部分上に、前記フルオロエラストマー
のフィルムと接触する内面を有する金属構造体を配置す
るステップ、並びに前記フルオロエラストマーのフィル
ムと前記非金属コア構造体の材料を共に硬化し前記フル
オロエラストマーのフィルムと前記金属構造体の前記内
面との間に結合を形成するために、十分な時間と熱と圧
力で、前記複合構造体を成形するステップを含んでなる
ことを特徴とする複合構造体の形成方法。1. A method for forming a composite structure, comprising: providing a core structure formed from an uncured non-metallic composite material, wherein uncured fluoroelastomer is provided on a surface portion of the core structure. Forming a film; disposing a metal structure having an inner surface in contact with the fluoroelastomer film on a portion of the core structure; and removing the fluoroelastomer film and the non-metal core structure material. Molding the composite structure for a time, heat and pressure sufficient to cure together and form a bond between the fluoroelastomer film and the inner surface of the metal structure. A method for forming a composite structure. 【請求項２】 前記成形するステップが、約３０分間、
約３６０°Ｆまでの温度、および約１００ｐｓｉから約
１０００ｐｓｉの圧力で実行されることを特徴とする請
求項１記載の方法。2. The method according to claim 1, wherein the forming step comprises:
The method of claim 1, wherein the method is performed at a temperature of up to about 360 ° F and a pressure of about 100 psi to about 1000 psi. 【請求項３】 前記配置するステップの前に前記金属構
造体の内面を活性化するステップをさらに含み、 前記活性化するステップは、前記内面をイソプロピルア
ルコール溶液により拭き取ることで前記内面を洗浄する
とともに望ましくない酸化物および他の有害な材料を取
り除くために前記内面をエッチングすることからなり、
並びに前記活性化するステップがさらに、前記内面上で
の望ましくない酸化物の形成を実質的に防止するととも
に前記内面の接着特性を改良するために、前記内面に対
する不溶性の腐食抑制剤を含むエポキシ樹脂溶液を塗っ
て前記内面を下塗するステップを含むことを特徴とする
請求項１記載の方法。3. The method according to claim 1, further comprising: activating an inner surface of the metal structure before the disposing step. The activating step includes cleaning the inner surface by wiping the inner surface with an isopropyl alcohol solution. Etching said inner surface to remove undesired oxides and other harmful materials;
And wherein the activating step further comprises an epoxy resin comprising an insoluble corrosion inhibitor for the inner surface to substantially prevent the formation of undesirable oxides on the inner surface and improve the adhesive properties of the inner surface. The method of claim 1 including the step of applying a solution to prime the interior surface. 【請求項４】 前記エッチングするステップが、前記内
面を備えた前記金属構造体を塩化第二鉄の酸性エッチン
グ溶液内でエッチングすることを含んでなることを特徴
とする請求項３記載の方法。4. The method of claim 3, wherein said etching step comprises etching said metal structure with said inner surface in a ferric chloride acidic etching solution. 【請求項５】 前記コア構造体を用意するステップが、
未硬化状態のグラファイト−エポキシ材料から形成され
た複合構造体を用意することからなり、 前記フィルムを形成するステップが、フッ化ビニリデン
とヘキサフルオロプロピレンの共重合体をベースとする
フルオロエラストマーのフィルムを未硬化状態で前記コ
ア構造体の前記表面部分上に形成することからなり、さ
らに前記金属構造体を配置するステップが鉄をベースと
する合金あるいはニッケルをベースとする合金から形成
された前縁構造体を前記コア構造体の前縁部分上に配置
することを含んでなることを特徴とする請求項１記載の
方法。5. The step of providing the core structure,
Providing a composite structure formed from an uncured graphite-epoxy material, wherein the step of forming the film comprises forming a film of a fluoroelastomer based on a copolymer of vinylidene fluoride and hexafluoropropylene. A leading edge structure formed from an iron-based alloy or a nickel-based alloy, wherein the step of disposing the metal structure comprises forming the metal structure in an uncured state on the surface portion of the core structure. The method of claim 1, comprising positioning a body on a leading edge portion of the core structure. 【請求項６】 硬化したグラファイトエポキシ材料から
形成されたコア構造体を用意するステップ、 フルオロエラストマーのフィルムを前記コア構造体の表
面部分に形成するステップ、 前記フルオロエラストマーのフィルムで覆われた前記コ
ア構造体の前縁部分上に金属の前縁構造体を配置するス
テップ、並びに前記フルオロエラストマーのフィルムを
備えた前記コア構造体および前記被覆された金属の前端
構造体をモールド内に配置するとともに共に硬化させ接
着を機能させるのに十分な時間だけ熱と圧力を加えるこ
とにより前記コア構造体と前記フルオロエラストマーの
フィルムの材料を共に硬化するとともに前記金属の前縁
構造体を前記コア構造体に接着するステップを含んでな
ることを特徴とするファン出口ガイドべーンの修復方
法。Providing a core structure formed from a cured graphite epoxy material; forming a fluoroelastomer film on a surface portion of the core structure; the core covered with the fluoroelastomer film. Disposing a metal leading edge structure on a leading edge portion of the structure, and placing and co-locating the core structure with the fluoroelastomer film and the coated metal leading end structure in a mold; The material of the core structure and the fluoroelastomer film are cured together by applying heat and pressure for a time sufficient to cure and function the bond and bond the metal leading edge structure to the core structure. Repairing a fan exit guide vane, comprising the steps of: 【請求項７】 前記前縁構造体を配置するステップがス
テンレススチールの前縁構造体を前記コア構造体の前記
前縁部分上に配置することを含んでなり、 前記方法が、前記ステンレススチールの前縁構造体の内
面をイソプロピルアルコール溶液で拭き取ることにより
前記コア構造体の前記前縁部分上に配置する前に前記ス
テンレススチールの前縁構造体を前処理し、前記ステン
レススチールの前縁構造体を室温で約１４分から１６分
の範囲の時間だけ塩化第二鉄のエッチング溶液内でエッ
チングし、およびその後に不溶性の腐食抑制剤を含むエ
ポキシ樹脂溶液で前記内面を下塗することをさらに含む
ことを特徴とする請求項６記載の方法。7. The step of disposing the leading edge structure comprises disposing a stainless steel leading edge structure on the leading edge portion of the core structure. Pre-treating the stainless steel leading edge structure prior to placing on the leading edge portion of the core structure by wiping an inner surface of the leading edge structure with an isopropyl alcohol solution, the stainless steel leading edge structure; Further etching at room temperature in a ferric chloride etching solution for a time ranging from about 14 minutes to 16 minutes, and subsequently priming said inner surface with an epoxy resin solution containing an insoluble corrosion inhibitor. 7. The method of claim 6, wherein: 【請求項８】 前記共に硬化させ接着するステップが約
３６０°Ｆまでの温度および約１００ｐｓｉから約１０
００ｐｓｉの圧力を約３０秒までの時間だけ加えること
を含んでなることを特徴とする請求項７記載の方法。8. The method of claim 1, wherein the co-curing and bonding step comprises a temperature of up to about 360.degree.
The method of claim 7, comprising applying a pressure of 00 psi for a time up to about 30 seconds. 【請求項９】 グラファイトエポキシ材料から形成され
たコア構造体を用意するステップ、 フルオロエラストマーのフィルムの接着剤を前記コア構
造体の表面部分に形成するステップ、 前記フルオロエラストマーのフィルムの接着剤で覆われ
た前記コア構造体の前縁部分上にステンレススチールの
前縁を配置するステップ、並びに前記フルオロエラスト
マーのフィルムの接着剤を備えた前記コア構造体および
前記被覆されたステンレススチールの前縁構造体をモー
ルド内に配置するともに共に硬化させ接着を機能させる
ために十分な時間だけ熱と圧力を加えることにより前記
コア構造体および前記フルオロエラストマーのフィルム
の接着剤材料を共に硬化するとともに前記ステンレスス
チールの前縁構造体を前記コア構造体に接着するステッ
プを含んでなることを特徴とするファン出口ガイドべー
ンの製造方法。9. Providing a core structure formed from a graphite epoxy material, forming a fluoroelastomer film adhesive on a surface portion of the core structure, covering with a fluoroelastomer film adhesive. Disposing a stainless steel leading edge on the leading edge portion of the core structure and the core structure and the coated stainless steel leading edge structure with the fluoroelastomer film adhesive. The core structure and the fluoroelastomer film adhesive material are cured together by placing heat and pressure for a time sufficient to place the molds in the mold and cure together to function the bond and the stainless steel. Step for bonding the leading edge structure to the core structure Fan exit guide vane manufacturing method characterized by comprising. 【請求項１０】 前記コア構造体の前記前縁上に配置す
る前に前記ステンレススチールの前縁構造体を前処理す
るステップをさらに含み、並びに前記前処理するステッ
プが、前記ステンレススチールの前縁構造体の内面をイ
ソプロピルアルコール溶液で拭き取り、前記ステンレス
スチールの前縁構造体を室温で約１４分から１６分の範
囲の時間だけ塩化第二鉄のエッチング溶液内でエッチン
グし、その後に不溶性の腐食抑制剤を含むエポキシ樹脂
溶液で前記内面を下塗することを含むことを特徴とする
請求項９記載の方法。10. The stainless steel leading edge structure further comprising the step of pre-treating the stainless steel leading edge structure prior to placing on the leading edge of the core structure, and wherein the pre-treating step comprises: The inner surface of the structure is wiped with an isopropyl alcohol solution, and the stainless steel leading edge structure is etched in a ferric chloride etching solution at room temperature for a time in the range of about 14 to 16 minutes, followed by insoluble corrosion control. 10. The method of claim 9, comprising priming the inner surface with an epoxy resin solution containing an agent. 【請求項１１】 前記共に硬化させ接着するステップ
が、約３０秒間の時間だけ約３６０°Ｆまでの温度およ
び約１００ｐｓｉから約１０００ｐｓｉの圧力を加える
ことを含んでなることを特徴とする請求項９記載の方
法。11. The method of claim 9, wherein the step of curing and bonding together comprises applying a temperature of up to about 360 ° F. and a pressure of about 100 psi to about 1000 psi for a time of about 30 seconds. The described method. 【請求項１２】 前記フルオロエラストマーのフィルム
の接着剤がフッ化ビニリデンとヘキサフルオロプロピレ
ンの共重合体をベースとするフルオロエラストマー材料
から形成されることを特徴とする請求項９記載の方法。12. The method of claim 9, wherein the fluoroelastomer film adhesive is formed from a fluoroelastomer material based on a copolymer of vinylidene fluoride and hexafluoropropylene. 【請求項１３】 非金属の複合材料から形成されたコア
構造体、 前記コア構造体の硬化温度に実質的に近い硬化温度を有
し、前記コア構造体の部分上に位置されたフルオロエラ
ストマーのフィルム材料、並びに前記フルオロエラスト
マーのフィルム材料上に配置された金属構造体を含んで
なることを特徴とする複合物。13. A core structure formed from a non-metallic composite material, comprising: a fluoroelastomer having a curing temperature substantially close to a curing temperature of the core structure and positioned on a portion of the core structure. A composite comprising a film material and a metal structure disposed on the fluoroelastomer film material. 【請求項１４】 前記コア構造体および前記フルオロエ
ラストマーのフィルム材料がそれぞれ約３５０°Ｆの硬
化温度を有していることを特徴とする請求項１３記載の
複合物。14. The composite of claim 13, wherein said core structure and said fluoroelastomer film material each have a cure temperature of about 350 ° F. 【請求項１５】 前記コア構造体が未硬化または実質的
に未硬化状態にある複合グラファイト−エポキシ材料に
より形成されるとともに、前記フルオロエラストマーの
フィルム材料が硬化または未硬化状態にあるフッ化ビニ
リデンとヘキサフルオロプロピレンの共重合体をベース
とするフルオロエラストマー材料により形成されている
ことを特徴とする請求項１３記載の複合物。15. The vinylidene fluoride wherein the core structure is formed of an uncured or substantially uncured composite graphite-epoxy material and the fluoroelastomer film material is in a cured or uncured state. 14. The composite of claim 13, formed from a fluoroelastomer material based on a copolymer of hexafluoropropylene. 【請求項１６】 前記金属構造体が鉄をベースとする合
金、ステンレススチールあるいはニッケルをベースとす
る合金から形成されていることを特徴とする請求項１５
記載の複合物。16. The metal structure according to claim 15, wherein the metal structure is formed from an iron-based alloy, stainless steel, or a nickel-based alloy.
A composite as described. 【請求項１７】 前記複合物が翼形からなり、前記金属
構造体が前記翼形の前縁を形成することを特徴とする請
求項１３記載の複合物。17. The composite of claim 13, wherein said composite comprises an airfoil, and wherein said metal structure forms a leading edge of said airfoil. 【請求項１８】 前記コア構造体およびフルオロエラス
トマーのフィルム材料が共に硬化されることを特徴とす
る請求項１３記載の複合物。18. The composite of claim 13, wherein the core structure and the fluoroelastomer film material are both cured.
JP9057351A 1996-05-29 1997-03-12 Method of forming composite structure and composite Expired - Fee Related JP2828168B2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US654,880 1991-02-11
US08/654,880 US5876651A (en) 1996-05-29 1996-05-29 Method for forming a composite structure

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JPH1016133A true JPH1016133A (en) 1998-01-20
JP2828168B2 JP2828168B2 (en) 1998-11-25

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EP (1) EP0813956B1 (en)
JP (1) JP2828168B2 (en)
KR (1) KR100219991B1 (en)
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SG (1) SG50822A1 (en)
TW (1) TW343173B (en)

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KR100219991B1 (en) 1999-09-01
US5876651A (en) 1999-03-02
EP0813956A1 (en) 1997-12-29
KR970074977A (en) 1997-12-10
EP0813956B1 (en) 1998-08-26
TW343173B (en) 1998-10-21
US5965240A (en) 1999-10-12
DE69700019D1 (en) 1998-10-01
DE69700019T2 (en) 1999-03-25
SG50822A1 (en) 1998-07-20

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